Lamp, lamp fan life predicting system and method thereof

ABSTRACT

The disclosure relates to a life prediction system for a fan of a lamp. The system comprises a fan signal detecting module to detect at least one working parameter of the fan; and a micro control unit to receive the working current signal, the environment temperature signal and the working rotation speed signal of the fan. The detecting module comprises a current detecting unit to detect a working current of the fan and output a working current signal; a temperature detecting unit to detect a working environment temperature of the fan and output an environment temperature signal; and a rotation speed detecting unit to detect and output a working rotation speed signal of the fan. The micro control unit calculates a predicted residual life of the fan based on the received working current signal, the environment temperature signal, the working rotation speed signal, through the life model of the fan.

TECHNICAL FIELD

The present application relates to a life prediction system for a fanand method thereof, and more particularly to a life prediction systemfor a fan of a lamp and method thereof, and a lamp to which the fan lifeprediction system is applied.

BACKGROUND

As a new-generation light source, an LED has the advantages of energysaving, environmental protection, long life, diversified colors, stablebeam, and high electro-optical conversion rate. It has become a trend touse the LED as a lighting source in recent years.

In some applications where the light intensity is high, due to the largeamount of thermal energy generated by the high-power LED light-emittingcomponents and the relatively harsh external environment that may exist,the internal temperature of the LED lamp may become too high, which willin turn affect the service life of the LED light-emitting components andother electronic components. Therefore, fans are commonly installedinside these LED lamps to maintain the internal temperature of the LEDlamps within a normal temperature range. However, during the use of thelamps, the wear and tear caused by the high load of the fan, theevaporation and oxidation of the lubricant in the fan caused by the hightemperature because of the closed environment, and the wear and tear tothe fan caused by the dust in the environment, which will all lead to adecrease in the service life of the fan, thereby reducing the servicelife of the entire lamp. Since the service life of the fan is generallyshorter than the service life of other electronic components of the LEDlamp, in general, the fan must be replaced during the use of the LEDlamp to ensure its normal operation.

In general, there are two strategies for fan replacement. One strategyis to periodically replace the fan, regardless of its actual operationalcondition. This may result in the replacement of a well-functioning fanand leading to waste, or it may result in a failure due to the fact thatsome fans having malfunctioned before reaching the end of their servicelife, thereby posing a safety hazard to the use of the entire system.Another strategy is to activate an alarm when the system temperature isdetected to exceed the normal range, and then repair or replace the fan;however, at such a time, the system is likely to have been damaged dueto the rise in temperature.

Therefore, it is necessary to provide a life prediction system for a fanof a lamp and a method thereof to solve the technical problems above.

SUMMARY

One aspect of the present application is to provide a life predictionsystem for a fan of a lamp, comprising: a fan signal detecting moduleand a micro control unit. A fan signal detecting module configured todetect at least one working parameter of the fan, comprising: a currentdetecting unit configured to detect a working current of the fan andoutput a working current signal; a temperature detecting unit configuredto detect a working environment temperature of the fan and output anenvironment temperature signal; and a rotation speed detecting unitconfigured to detect and output a working rotation speed signal of thefan. A micro control unit is configured to receive the working currentsignal, the environment temperature signal and the working rotationspeed signal of the fan, with the micro control unit comprising astorage unit configured to store a life model of the fan. Wherein, themicro control unit is configured to calculate a predicted residual lifeof the fan based on the working current signal, the environmenttemperature signal, the working rotation speed signal and the lifemodel.

Another aspect of the present application is to provide a method forpredicting the life for a fan of a lamp, comprising: detecting a workingcurrent of the fan and outputting a working current signal; detecting aworking environment temperature of the fan and outputting an environmenttemperature signal; detecting and outputting a working rotation speedsignal of the fan; and receiving the working current signal, theenvironment temperature signal and the working rotation speed signal andcalculating a predicted residual life of the fan based on a life modelof the fan.

Yet another aspect of the present application is to provide a lamp,comprising a fan and a fan signal detecting module configured to detectat least one working parameter of the fan. The fan signal detectingmodule comprising: a current detecting unit configured to detect aworking current of the fan and output a working current signal; atemperature detecting unit configured to detect a working environmenttemperature of the fan and output an environment temperature signal; anda rotation speed detecting unit configured to detect and output aworking rotation speed signal of the fan. Wherein, the working currentsignal, the environment temperature signal and the working rotationspeed signal of the fan are to be received at a micro control unit,comprising a storage unit configured to store a life model of the fan.The micro control unit is configured to calculate a predicted residuallife of the fan based on the working current signal, the environmenttemperature signal, the working rotation speed signal and the lifemodel.

One of the purposes of the present application is to design a lifeprediction system for a fan of a lamp to predict the residual life ofthe fan, so that effective measures can be taken in a timely manner toavoid damage to the entire lamp system due to fan failure.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the present application are described with reference tothe accompanying drawings, so that the present invention can be betterunderstood. In the accompanying drawings:

FIG. 1 is a perspective view of a lamp according to an embodiment of thepresent invention.

FIG. 2 is an exploded view of the lamp of FIG. 1 .

FIG. 3 is a cross-sectional view of the lamp of FIG. 1 taken along lineA-A.

FIG. 4 is a functional block diagram of a life prediction system for afan of a lamp according to an embodiment of the present invention.

FIG. 5 is a functional block diagram of a life prediction system for afan of a lamp according to another embodiment of the present invention.

FIG. 6 is an exploded view of a lamp according to another embodiment ofthe present invention.

FIG. 7 is a functional block diagram of a life prediction system for afan of a lamp according to still another embodiment of the presentinvention.

FIG. 8 is a flow chart showing a method for predicting the life of a fanof a lamp according to an embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

Unless defined otherwise, the technical terms or scientific terms usedherein should have ordinary meanings construed by those of ordinaryskill in the art to which the present application belongs. The “first”,“second” and similar words used in the patent specification and claimsof the present invention do not denote any order, quantity orimportance, but are merely intended to distinguish between differentconstituents. Similarly, the terms “one”, “a”, and similar words are notmeant to be limiting, but rather denote the presence of at least one.“Comprising”, “consisting”, and similar words mean that elements orarticles appearing before “comprising” or “consisting” include theelements or articles and their equivalent elements appearing behind“comprising” or “consisting”, not excluding any other elements orarticles. “Connected”, “coupled” and similar words are not restricted tophysical or mechanical connections, but may also include electricalconnections, whether direct or indirect.

The fan life prediction system of the lamp of the present applicationcan be applied to various high-power illumination lamps with a heatdissipation fan, including but not limited to light-emitting diode (LED)lamps, organic light-emitting diode (OLED) lamps, fluorescent lamps, andhigh-intensity discharge (HID) lamps. A detailed description will beprovided below by using an LED lamp as an example.

FIG. 1 is a perspective view of a lamp 100 of an embodiment. FIG. 2 isan exploded view of the lamp 100 of FIG. 1 . FIG. 3 is a cross-sectionalview of the lamp 100 of FIG. 1 taken along line A-A.

As shown in FIGS. 1, 2, and 3 , the lamp 100 comprises a base 102, abase housing 104, a heat dissipation module 106, at least one printedcircuit board 108, a driving module 110, a lamp housing 112, and a fanmodule 114. The fan module 114 comprises a fan 116 and a cover 118. Insome embodiments, to facilitate disassembly and assembly of the fan 116,the lamp 100 further comprises a connection device 120 that isdetachably coupled to the cover 118. The base 102 is mounted in aconventional lamp holder or socket and is electrically connected to anexternal power source. One end of the base housing 104 and the base 102coupled through a threaded connection, and the other end is used toconnect and secure the heat dissipation module 106, the printed circuitboard 108, the driving module 110, and the lamp housing 112. Wherein,the driving module 110 is electrically connected to the base 102 and theprinted circuit board 108 for driving at least one light emitting diode128 on the printed circuit board 108. The heat dissipation module 106 isfixed between the base housing 104 and the connecting device 120 with ascrew, clip, or adhesive. At least one printed circuit board 108 ismounted around the periphery of the heat dissipation module 106, theheat dissipation module 106 is in thermal contact with the lightemitting diodes 128 through the printed circuit board 108 fordissipating heat generated by the light emitting diodes 128.

In some embodiments, as shown in FIGS. 2 and 3 , the lamp 100 furthercomprises a communication module 126 that is secured to the cover 118and a top cover 124 that protects the communication module 126. Thecommunication module 126 is selected from at least one of a microwavecommunication module, a Bluetooth communication module, a Wi-Ficommunication module, a mobile communication module, a universal packetwireless service technology communication module and a ZigBeecommunication module. In some embodiments, the top cover 124 also coversa sensor (not shown) secured to the cover 118, wherein the sensorcomprises at least one of a daylight sensor, a motion sensor, a humanbody sensor, an audio sensor, a temperature sensor, a humidity sensor,and an air quality sensor.

FIG. 4 is a functional block diagram of life prediction system 400 for afan of a lamp of one embodiment. The life prediction system 400 for afan of the lamp comprises a fan signal detecting module 430, acommunication module 126, and a server 438. The fan signal detectingmodule 430 comprises a current detecting unit 432, a temperaturedetecting unit 434, and a rotation speed detecting unit 436. The server438 comprises a micro control unit 440 that comprises a storage unit 442for storing a life model of the fan. After confirming the model of thefan, based on the cycle life data of that model under different workingconditions, through modeling simulation and calculation analysis, thelife model for this particular model of the fan is then established. Inthe life model of the present embodiment, the predicted residual life ofthe fan and the working current of the fan, the ambient temperature atwhich the fan operates, and the rotational speed of the fan are related,that is, LIFE=f(T, I, RPM), wherein LIFE is a prediction of the residuallife of the fan, T is the working temperature of the fan, I is theworking current of the fan, and RPM is the working rotational speed ofthe fan. According to the life model, the predicted life of the fanunder different working conditions can be calculated more accurately,which can be sent to the customer to provide a reference for the optimalfan replacement strategy.

In some embodiments, the fan is a ball bearing type, and the life modelof the ball bearing fan can be calculated using the following formula:

${LIFE} = {a*e^{\frac{b}{T + 273.15}}*\frac{2^{- I^{2}}}{RPM}}$

Wherein, LIFE: the predicted residual life of the fan, the unit is hour;T: the working temperature of the fan, the unit is ° C.; I: the workingcurrent of the fan, the unit is A; RPM: the working rotational speed ofthe fan, the unit is rpm; b is a constant, and in one embodiment, a=411,b=4,421.5. In other embodiments, the values of a and b can be adjusteddepending on the fan model and/or working conditions.

In some embodiments, the fan is of the brush type and its life model canalso be established by modeling simulation and computational analysis.

Please continue to refer to FIGS. 2 and 4 , where:

The current detecting unit 432 is disposed inside the power circuit ofthe fan 116 for detecting the working current of the fan 116 andconverting the detected current into a working current signal output. Insome embodiments, the current detecting unit 432 is mounted on thedriving module 110 and is electrically connected by a wire to the fan116. In some embodiments, the current detecting unit 432 mounted on thedriving module 110 can be directly coupled to the power supply circuitof the fan 116 on the driving module 110.

The temperature detecting unit 434 is disposed at the air inlet or theair outlet of the fan 116 for detecting the ambient temperature at whichthe fan 116 operates, and converting the detected ambient temperatureinto an ambient temperature signal output. The temperature detectingunit 434 is selected from a thermal resistor, a thermistor, athermocouple, and an integrated temperature sensor, wherein thethermistor comprises a negative temperature coefficient (NTC) thermistorand a positive temperature coefficient (PTC) thermistor. In someembodiments, the current detecting unit 432 is mounted on the printedcircuit board 108 at the air inlet of the fan 116 at an end near the fan116. In some embodiments, the current detecting unit 432 is mounted onthe driving module 110 at the air outlet of the fan 116 at an end nearthe fan 116.

The rotation speed detecting unit 436 is for detecting and outputtingthe working rotational speed signal of the fan 116. The rotational speeddetecting unit 436 obtains a working rotational speed signal of the fan116 by using an infrared or visible electromagnetic wave signal emittedfrom the transmitter to be received by the receiver through reflection.In some embodiments, the rotational speed detecting unit 436 is mountedon the driving module 110 at an end near the fan 116. In someembodiments, the rotational speed detecting unit 436 is mounted on theheat dissipation module 106 at an end near the fan 116.

The communication module 126 is coupled to the fan signal detectingmodule 430 for receiving and transmitting the working current signal,the ambient temperature signal, and the working rotational speed signalto the micro control unit 440 in the server 438 by way of wirelesstransmission. The micro control unit 440 and lamp 100 are separatelydisposed, and in some embodiments, the micro control unit 440 is faraway from the lamp 100. The communication module 126 is secured to thecover 118 of the lamp 100. In other embodiments, the communicationmodule can be mounted elsewhere on the lamp 100, such as on the outsideof the base housing 104.

The micro control unit 440 receives the working current signal, theambient temperature signal, and the working rotational speed signal ofthe fan 116 from the communication module 126, and calculates thepredicted residual life of the fan 116 by using the life model of thefan 116, and then transmits the calculated predicted residual life tothe server 438.

The server 438 is configured to receive the predicted residual lifecalculated by the micro control unit 440 and then transmit the predictedresidual life to the client. The server 438 transmits the predictedresidual life of fan 116 to the client over a wired network, wirelessnetwork, or other microwave signals. The client can be a variety of PCs(personal computers) or handheld electronic devices. In someembodiments, the server is configured to transmit the current predictedresidual life and fan replacement signal to the client when thepredicted residual life of the fan 116 is less than or equal to the setlifetime threshold. The lifetime threshold may be configured or adjustedby the user on the client according to different applications andconditions.

FIG. 5 is a functional block diagram of a fan life prediction system 500for a lamp of another embodiment. The fan life prediction system 500 ofthe lamp comprises a fan signal detecting module 530, a micro controlunit 540, a communication module 126, and a repeater 538. The fan signaldetecting module 530 comprises a current detecting unit 532, atemperature detecting unit 534, and a rotation speed detecting unit 536.The micro control unit 540 comprises a storage unit 542 for storing alife model of the fan.

Please continue to refer to FIGS. 2 and 5 , where:

The functions and positions of the current detecting unit 532, thetemperature detecting unit 534, and the rotational speed detecting unit536 are substantially identical to those of the current detecting unit432, the temperature detecting unit 434, and the rotational speeddetecting unit 436 in the embodiment of FIG. 4 , and the descriptionthereof will not be repeated here.

The micro control unit 540 receives the working current signal, theambient temperature signal and the working rotational speed signal ofthe fan 116 from the current detecting unit 532, the temperaturedetecting unit 534, and the rotational speed detecting unit 536, andobtain the predicted residual life of the fan 116 calculated by usingthe life model of the fan 116, and then the calculated predictedresidual life is transmitted to the communication module 126. Wherein,the micro control unit 540 and the lamp 100 are integrated. In someembodiments, the micro control unit 540 can be mounted on the drivingmodule 110. In some embodiments, the micro control unit 540 can also bemounted to the cover 118 at a location adjacent to the communicationmodule 126.

The communication module 126 is coupled to the micro control unit 540for receiving and transmitting the calculated predicted residual life ofthe fan 116 to the client by way of wireless transmission. Thecommunication module 126 is secured to the cover 118 of the lamp 100. Insome embodiments, between a communication module 126 and the clientfurther comprises a repeater 538, the repeater 538 receives thepredicted residual life signal of the fan 116 transmitted from thecommunication module 126, which is retransmitted to the client, therebyachieving a higher data rate and output transmission over longerdistances.

FIG. 6 shows an exploded view of a lamp 600 of another embodiment. Thelamp 600 comprises a base 602, a base housing 604, a heat dissipationmodule 616, at least one printed circuit board 608, a driving module610, a lamp cover 612, and a fan module 614. A display module 644 ismounted onto the lamp cover 612.

FIG. 7 is a functional block diagram of a fan life prediction system 700for a lamp of still another embodiment, comprising a fan signaldetecting module 730, a micro control unit 740, and a display module644. The fan signal detecting module 730 comprises a current detectingunit 732, a temperature detecting unit 734, and a rotation speeddetecting unit 736. The micro control unit 740 comprises a storage unit742 for storing a life model of the fan.

Please continue to refer to FIGS. 6 and 7 , where:

The functions and positions of the current detecting unit 732, thetemperature detecting unit 734, and the rotational speed detecting unit736 are substantially identical to those of the current detecting unit532, the temperature detecting unit 534, and the rotational speeddetecting unit 536 in the embodiment of FIG. 5 , and the descriptionthereof will not be repeated here.

The micro control unit 740 receives the working current signal, theambient temperature signal and the working rotational speed signal ofthe fan 116 from the current detecting unit 732, the temperaturedetecting unit 734, and the rotational speed detecting unit 736, andobtain the predicted residual life of the fan 116 calculated by usingthe life model of the fan 116, and then the calculated predictedresidual life is transmitted to the display module 644. In someembodiments, the micro control unit 740 is integrated with the lamp 600.

The display module 644 is coupled to the micro control unit 740 forreceiving and displaying the predicted residual life calculated by themicro control unit 740. The technician can be made clearly andintuitively aware of the predicted residual life of the fan 616 in orderto determine when to replace the fan 616.

Please refer to FIG. 8 , which is a flowchart of a method 800 forpredicting the life of the fan 116 of the lamp of one embodiment. Themethod 800 comprises the following steps:

Step 802, detecting a working current of the fan 116 and outputting aworking current signal.

Step 804, detecting an ambient temperature at which the fan 116operates, and outputting an ambient temperature signal.

Step 806, detecting and outputting the working rotational speed signalof the fan 116.

Step 808, receiving a working current signal, an ambient temperaturesignal, and a working rotational speed signal of the fan 116, andcalculating a predicted residual life of the fan 116 according to thestored life model of the fan 116.

Step 810, setting a fan life threshold, and transmitting a predictedresidual life and a fan replacement signal to the client when thepredicted residual life of the fan 116 is less than or equal to the fanlife threshold.

In some embodiments, step 808 may comprise the following sub-steps:

Step 8081: Receive a working current signal, an ambient temperaturesignal, and a working rotational speed signal of the fan 116 andtransmit the signal to the micro control unit.

Step 8082: Calculate the predicted residual life of the fan 116according to the received working current signal of the fan 116, theambient temperature signal, and the working rotational speed signal andthe stored life model of the fan 116.

In some embodiments, step 810 may comprise the following sub-steps:

Step 8101: Receive the predicted residual life of the fan 116, transmitthe predicted residual life to the client, or display the predictedresidual life through the display module.

Step 8102: When the predicted residual life of the fan 116 is less thanor equal to the fan life threshold, the predicted residual life and thefan replacement signal are sent to the client.

As can be seen from the above description, the present applicationcalculates the predicted residual life of the fan according to thepre-stored fan life model by using the working current, the ambienttemperature and the working rotational speed during the fan operationalprocess, providing a maintenance and replacement strategy for the fan,thereby improving the reliability of the system's operation.

Although the present invention has been described with reference tospecific embodiments, persons skilled in the art may understand thatmany modifications and variations can be made to the present invention.It is, therefore, to be understood that the appended claims are intendedto cover all such modifications and variations insofar as they arewithin the concept and scope of the invention.

The invention claimed is:
 1. A life prediction system for a fan of alamp, comprising: a fan signal detecting module configured to detect atleast one working parameter of the fan, comprising: a current detectingunit configured to detect a working current of the fan and output aworking current signal; a temperature detecting unit disposed at atleast one of an air inlet or an air outlet of the fan, the temperaturedetecting unit being configured to detect a working environmenttemperature of the fan and output an environment temperature signal; arotation speed detecting unit configured to detect and output a workingrotation speed signal of the fan; and a communication device to transmitthe working current signal, the environment temperature signal and theworking rotation speed signal of the fan to a micro control unit locatedremote from the fan signal detecting module, the micro control unitcomprising a storage unit configured to store a life model for aparticular model of the fan; wherein the micro control unit isconfigured to confirm that the fan has the particular model and,responsive to conforming that the fan has the particular model,calculate a predicted residual life of the fan based on the workingcurrent signal, the environment temperature signal, the working rotationspeed signal and the life model for the particular model of the fan, themicro control unit transmitting the predicted residual life value fordelivery to at least one client in conjunction with a fan replacementsignal when the predicted residual life is less than or equal to apre-set life threshold.
 2. The life prediction system according to claim1, further comprising a server comprising the micro control unit,wherein the server is configured to send the predicted residual life toat least one client.
 3. The life prediction system according to claim 1,wherein the communication module is mounted on the cover of the lamp,and the communication module is selected from at least one of amicrowave communication module, a Bluetooth communication module, aWi-Fi communication module, a Mobile communication module, a Universalpacket wireless service technology communication module and a ZigBeecommunication module.
 4. The life prediction system according to claim1, further comprising a repeater configured to receive the predictedresidual life from the micro control unit and send the predictedresidual life to the client.
 5. The life prediction system according toclaim 1, further comprising a display module mounted on the cover of thelamp and configured to display the predicted residual life calculated bythe micro control unit.
 6. A method for predicting a life for a fan of alamp, comprising: receiving, from a client device, a life thresholdassociated with the fan; detecting, by a current detecting unit, aworking current of the fan and outputting a working current signal;detecting, by a temperature detecting unit disposed at at least one ofan air inlet or an air outlet of the fan, a working environmenttemperature of the fan and outputting an environment temperature signal;detecting and outputting, by a rotation speed detecting unit, a workingrotation speed signal of the fan; transmitting the working currentsignal, the environment temperature signal and the working rotationspeed signal to a micro control unit located remote from the currentdetecting unit, the temperature detecting unit, and the rotation speeddetecting unit, wherein the micro control unit is configured to confirmthat the fan has the particular model and, responsive to conforming thatthe fan has the particular model, calculate a predicted residual life ofthe fan based on a life model of the fan; and transmitting the predictedresidual life and a fan replacement signal to a client device if thepredicted residual life is less than or equal to the life threshold. 7.A lamp including a fan, the lamp comprising a fan signal detectingmodule configured to detect at least one working parameter of the fan,the fan signal detecting module comprising: a current detecting unitconfigured to detect a working current of the fan and output a workingcurrent signal; a temperature detecting unit disposed at at least one ofan air inlet or an air outlet of the fan, the temperature detecting unitbeing configured to detect a working environment temperature of the fanand output an environment temperature signal; a rotation speed detectingunit configured to detect and output a working rotation speed signal ofthe fan; and a communication device to transmit the working currentsignal, the environment temperature signal and the working rotationspeed signal of the fan to a micro control unit located remote from thefan signal detecting module, the micro control unit comprising a storageunit configured to store a life model for a particular model of the fan;wherein the micro control unit is configured to confirm that the fan hasthe particular model and, responsive to conforming that the fan has theparticular model, calculate a predicted residual life of the fan basedon the working current signal, the environment temperature signal, theworking rotation speed signal and the life model for the particularmodel of the fan, the micro control unit transmitting the predictedresidual life value for delivery to at least one client in conjunctionwith a fan replacement signal when the predicted residual life is lessthan or equal to a pre-set life threshold.